Cermet body

ABSTRACT

A tooling assembly, including a cermet tool body and an electrically nonconductive polymer support body at least partially encapsulating the cermet tool body. The cermet tool body and electrically nonconductive polymer body further include a plurality of high magnetic permeability metallic particles distributed therethrough. Each respective high magnetic permeability metallic particle has a magnetic permeability of at least 0.0001 H/m. Each respective high magnetic permeability metallic particle has a relative permeability of at least 100.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to U.S. provisional patent application Ser. No. 62/778,380, filed on Dec. 12, 2018, and also to U.S. co-pending patent application Ser. No. 15/792,063, filed Oct. 24, 2017, which claimed priority to U.S. provisional patent application Ser. No. 62/411,894, filed on Oct. 24, 2016, as well as to U.S. provisional patent application Ser. No. 62/426,827, filed on Nov. 28, 2017, and U.S. provisional patent application Ser. No. 62/532,686, filed on Jul. 14, 2017, and which was a continuation-in-part of, and claimed priority to, then co-pending U.S. patent application Ser. No. 14/822,136, filed on Aug. 10, 2015, and issued as U.S. Pat. No. 9,815,743 on Nov. 14, 2017, which was a continuation in part of, and claimed priority to, then U.S. patent application Ser. No. 13/890,743, filed on May 9, 2013, and issued on Jun. 6, 2017, as U.S. Pat. No. 9,670,101, and which claimed priority to then co-pending U.S. provisional patent application Ser. No. 61/644,610, filed May 9, 2012, and to then co-pending U.S. provisional patent application Ser. No. 61/752,086, filed Jan. 14, 2013, and was also a continuation-in-part of, and claimed priority to, co-pending U.S. patent application Ser. No. 14/192,815, filed on Feb. 27, 2014, which claimed priority to then co-pending U.S. provisional patent application Ser. No. 61/770,269, filed on Feb. 27, 2013, each of which are incorporated herein by reference.

TECHNICAL FIELD

The novel technology disclosed herein relates generally to the field of ceramic materials and, more particularly, to a theoretically dense sintered ceramic material that exhibits strong paramagnetic and/or ferromagnetic properties.

BACKGROUND

Tooling involved in the production of food and pharmaceuticals is typically metallic. Although ceramic materials have superior compressive properties, they are brittle and tend to chip. Thus, ceramic tooling is considered unsuitable for use with food and/or pharmaceuticals, since ceramic chips or fragments are difficult to detect and can contaminate the foodstuffs and/or pharmaceutical materials. Thus, there remains a need for ceramic tooling enjoying superior compression strengths along with easy detection of chips and fragments for screening and removal. The present novel technology addresses this need.

One tool of particular utility in the pharmaceutical industry is the compaction die. The compaction die is an isostatic pressing device utilized in the production of tablets utilized in, and not limited to, the following industries: battery, pharmaceuticals, nutraceuticals, cosmetics, confectionary, food, pet food, chlorine and industrial tablets. Such dies are commonly used on tablet presses and the like to compact powders into green bodies so as to produce tablets or other compacted shapes.

Thus, there remains a need for ceramic tooling enjoying superior compression strengths along with easy detection of chips and fragments for screening and removal. The present novel technology addresses this need.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side plan view of a cermet piston assembly according to a first embodiment of the present novel technology.

FIG. 1B is a side cutaway view of the embodiment of FIG. 1A.

FIG. 1C is top plan view of the mandrel portion of the piston assembly embodiment of FIG. 1A.

FIG. 2A is a front perspective view of the embodiment of FIG. 1A.

FIG. 2B is a partial side cutaway elevation view of the embodiment of FIG. 1A.

FIG. 3 is a side cutaway elevation view of the embodiment of FIG. 1A.

FIG. 4 schematically illustrates a typical sintering profile of the cermet material of FIG. 1A.

FIG. 5 is a perspective view of the piston assembly of claim 1 supported in a metal-detectible plastic belt.

FIG. 6 is a diagrammatic view of a second embodiment a ceramic-plastic implementation from the present novel technology.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the novel technology and presenting its currently understood best mode of operation, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel technology is thereby intended, with such alterations and further modifications in the illustrated device and such further applications of the principles of the novel technology as illustrated therein being contemplated as would normally occur to one skilled in the art to which the novel technology relates.

The present novel technology relates to ceramic or cermet compositions that may be formed into sintered and densified ceramic bodies that enjoy the physical toughness, strength and wear resistance of ceramics while being detectible by conventional metal detection techniques. These cermet compositions may then be formed into such bodies as metal-detectible ceramic tooling or the like, thus offering improved safety features by increased ability to detect any small contaminate.

In one embodiment, the cermet composition includes a ceramic matrix phase such as ZrO₂, yttria stabilized zirconia (YSZ), Gd₂O₃, and combinations thereof, with a metallic phase such as Ni, Fe, Co, permalloy, Mu-metal, and combinations thereof, dispersed therein. The metallic phase is typically introduced in oxide form for reduction to metallic form during processing, to avoid mixing issues arising from significant density differences as well as metallic species chemically interacting with oxide species at elevated temperatures. Alternately, some or all of the metallic phase component may be introduced as metallic species.

The metallic phase may be an alloy, and the alloy may be introduced as metal alloy particles, particles of oxidized alloy, or as oxides of the constituent metals for reduction and subsequent alloying of the resulting metals. The metallic phase typically has a high magnetic permeability μ of at least about 1×10⁻⁴ H/m, more typically μ being at least about 1×10⁻³ H/m, still more typically μ being at least about 1×10⁻² H/m, and yet more typically μ being about 5×10⁻² H/m. The metallic phase typically has a relative permeability μ/μ₀ of at least about 100, more typically at least about woo, still more typically of at least about 10,000, and yet more typically of at least about 20,000, and in some cases, μ/μ₀ may exceed 50,000 or more.

In some specific examples, the metallic phase typically has a high magnetic permeability μ of at least about 1×10⁻⁴ H/m with a relative permeability μ/μ₀ of at least about 100, more typically μ being at least about 5×10⁻³ H/m and μ/μ₀ at least about 4000, still more typically μ being at least about 1×10⁻² H/m and μ/μ₀ at least about 8000, and yet more typically μ being about 2.5×10⁻² H/m and μ/μ₀ 20,000. In some cases, μ/μ₀ may exceed 50,000 or more.

Typically, the matrix and metallic phase materials are provided as precursor powders, more typically as a homogeneous admixture, with the metallic phase present in sufficient quantity to yield between about 1 volume percent and about 20 volume percent metallic particles to the resultant cermet body, with about 80 to about 99 volume percent of the powder giving rise to the ceramic matrix phase, and with about 1 to about 8 weight percent of organic additives. A typical composition has less than 10 volume percent of the powder that gives rise to the metallic phase, with the balance being given to the powder giving rise to the ceramic matrix phase and, optionally a small amount of organic additives. If the powder giving rise to the metallic phase is a reducible material (e.g., a metal oxide), the volume percent of initial precursor powder is typically appropriately adjusted to compensate for the loss of the species (e.g., oxygen) that is removed during firing in a reducing atmosphere.

Typically, the matrix phase is a stable, structural ceramic, such as ZrO₂, yttria stabilized zirconia (YSZ), Gd₂O₃, or the like, and may include such materials as the various stabilized zirconias, zirconia-toughened alumina, alumina, TiB₂, ZrB₂, HfB₂, TaB₂, TiC, Cr₃C₂, and the like, and mixtures thereof.

The cermet composition may be prepared by any process that yields a monolithic part, typically having a well-blended mixture of the ceramic matrix phase and the oxide precursor phase, that will yield the metallic phase upon firing in a reducing environment. This may include preparation by slip casting, extrusion, freezing, and the like. One typically selected method is dry pressing, such as uniaxial pressing, cold isostatic pressing, hot isostatic pressing, and the like.

The appropriate powder preparation method is dictated by the selected method for processing the cermet composition. Dry pressing the powder giving rise to the ceramic matrix phase and the powder giving rise to the metallic phase are homogenized through mixing/blending to define an admixture. Additionally, organic additives such as surfactants, binders and the like may be present in small amounts to aid in powder processing, green body formation, and the like. Typically, these organic additives may be dissolved in a suitable liquid to be gradually added to the mixed inorganic powders in a shear granulation process. One typical powder preparation method includes preparing a suspension of the mixed inorganic powders and organic additives for drying to yield press ready granules.

In the case of an oxide powder precursor for yielding a metal alloy phase (i.e., a metal consisting of more than one element), it is preferred that the multiple oxide powders be calcined together at suitably high temperatures to generate a multi-elemental reaction product that is subsequently milled to a particle size that is appropriate for subsequent powder processing. Alternatively, predetermined amounts of constituent metals may be mixed and fused, with the fusion product allow later milled into a metallic powder precursor to yield an admixture.

The homogeneous admixture is then formed into a green body. Typically, the admixture is introduced into a mold and pressed into a green body. In some embodiments, small amounts of binder are introduced to assist the green body in retaining its shape after formation. The green body is then sintered at elevated temperatures and under controlled, reducing atmospheric compositions. A majority of the non-matrix metal oxide portion is reduced to yield a sintered cermet body having a predetermined amount of metallic particles dispersed in a sintered ceramic, typically oxide, matrix. In some instances, the admixture is introduced into a mold and then formed directly into a sintered cermet body, such as through a hot isostatic pressing (HIP) technique.

Generally, the admixture is heated at one to ten degrees Celsius per minute until a peak temperature between 1400 and 1700 degrees Celsius is reached. Then the admixture is held at this peak temperature for no greater than four hours. This is followed by a cool down by decreasing the temperature of the admixture between one to 5 degrees Celsius per minute until a temperature between 1200 and 1400 degrees Celsius is reached. The admixture is to dwell in this temperature range for duration of one to six hours. Then the admixture is to be brought down to room temperature at a rate of one to ten degrees Celsius per minute. The admixture may be processed in powder form, or as pressed into body. The metal particle size and distribution is influenced by the firing time and temperature. For example, longer firing times and/or greater firing temperatures typically yield larger metallic particles.

Once a sintered body is produced, it may be further machined into a desired shape. Further, the sintered body, before and/or after machining, may be soaked at an elevated temperature in a reducing atmosphere, such as annealing in hydrogen, to improve its ability to be sensed by a metal detector. Other generally appropriate reducing atmospheres may include a forming gas (i.e., hydrogen blended with an inert gas at various ratios), ammonia, vacuum, and combinations of the like.

In one embodiment, the green body is chemically activated to yield a densified ceramic matrix having a plurality of metallic particles dispersed therethrough.

In one embodiment, the sintered, densified cermet bodies are formed as pill-making tooling. The pill-making tooling enjoys the benefits of ceramic composition, including compression strength, toughness, durability, corrosion resistance, low coefficient of friction, low thermal expansion coefficient, and the like. The tooling enjoys the advantages of the advanced ceramic with the additional ability of being identified by conventional metal detection technology.

Other embodiments of the sintered, densified cermet bodies include equipment and tooling for the processing of foods and beverages, for pharmaceutical manufacture and processing, medical diagnostic devices and tools, military hardware, weapons, metal blades and cutting tools, industrial tooling and machinery, punches and dies, and the like.

In operation, tooling made from the novel cermet material functions similarly to traditional metal tooling, with the exception of typically requiring less lubricant and maintenance. This is advantageous for tooling associated with the production of pharmaceuticals and foodstuffs, such as pills, vitamins, and the like, as there is an associated reduction of discoloration (i.e., black marks) of the final product. Further, the novel cermet tooling is typically formed as a single piece, as contrasted to traditional multipiece tooling (i.e., metal punch having a ceramic tip), and thus the incidence of attached tooling pieces becoming dislodged during use is eliminated.

Typically, a production line utilizing the novel cermet tooling will have metal detectors for detecting and screening tooling chips from product. Typically, metal detectors employ an electric generator for producing an alternating electric field and a magnetometer for detecting magnetic fields. The electric generator produces an alternating electric field which generates eddy currents in electrically conductive materials; the eddy currents give rise to magnetic fields, which may be detected by the magnetometer. The tooling chip contaminants contain electrically conductive metallic particles which react to the magnetometer. Chips are thus removed from product upon detection. In some embodiments, the novel cermet material is sufficiently ferromagnetic as to be magnetically sortable from nonmagnetic product. Further, the novel cermet is advantageous in that, with the proper selection of alloy having high magnetic permeability, it has an ability to be detected at smaller sized particles than ferrous tool steel. For the given magnetic permeabilities of this material, as discussed above, tooling chips having diameters of 0.5 mm may be typically detected and magnetically or otherwise removed, and more typically chips having diameters of 0.3 mm may be detected and magnetically or otherwise removed.

Moreover, the cermet material is substantially harder and tougher than tool steel. In some embodiments, soft ferrite is used as a stabilizer, supplementing or replacing magnesia, yttria, or like compositions with soft ferrite and/or permalloy. This can be added to materials such as alumina, mullite, ZTA, or the like and toughen up the material and provide a low cost hard material with enhanced toughness. Likewise, SiC, graphite, graphene, or like other fibers and/or whiskers may be added to provide additional toughness and strength.

Thus the novel cermet allows for possible abrasion resistance of up to 4 to 5 times what is allowed by typical tool steel.

The following example is merely representative of the work that contributes to the teaching of the present novel article, and the novel material is not intended to be restricted by the following example.

Example 1

This example relates to a novel method of manufacturing the novel material starting with a Ni/Fe super alloy which is then ground up, milled and mixed with a zirconium ceramic powder to yield a slurry. Wherein the metallic alloy is present in generally sufficient quantities between typically between about 2 and about 8 weight percent of the total (more typically between about 0.5 and about 20 volume percent of resultant cermet body.) The slurry is then spray dried prior to yield a powder precursor, which may be formed into a green body for sintering.

Generally, the sintering steps occur in oxygen-free conditions and the ceramic composition may first be calcined by firing in an ambient atmosphere in order to generally remove any organic additives (binders, dispersants, etc.). Burnout is accomplished by slowly heating the ceramic material between the region of 300 to 400 degrees Celsius, then continuing to heat the composition until appropriate temperature (on the order of 900 to 1100° C.) to bisque fire the composition has been reached, thereby imparting some strength. The bisque fired composition can then be heated in a separate step, using the previously discussed heating profile ranges, under vacuum or a reducing atmosphere to convert the reducible component to a metal while simultaneously sintering the cermet.

Alternatively, the ceramic composition may be fired in a single cycle. The binder burnout portion of the cycle is typically performed in air. Typically, the firing atmosphere remains air until a temperature range of between about 900 and about 1100 degrees Celsius, at which point the firing atmosphere is purged of air and replaced with a reducing atmosphere. Typically, waiting until the temperature range of 900 to 1100 degrees Celsius reduces the likelihood of sequential reduction reactions of single metallic elements in a powder that is intended to give rise to a metal alloy phase. Thus, the atmosphere typically remains as a reducing atmosphere for the remainder of the firing cycle, including the cool down phase. The oxygen content of the sintering atmosphere may be determined by the amount and nature of the ferrite material portion of the cermet composition, if any. For some compositions, microwave sintering is the preferred sintering process.

Once the sintered body is produced, it is typically annealed in hydrogen or other appropriate reducing atmospheres to improve its ability to be sensed by a metal detector. The sintered body will typically have a density of substantially theoretical (in excess of 99 percent, more typically in excess of 99.9 percent dense), bulk density of about 6 g/cc, hardness of about 1100-1500 HV, flexural strength of about 200 kPSI, compressive strength of about 2000 kPSI, toughness of 12-14 MPa·m^(1/2) (K1c), modulus of 210-230 GPa, and a relative permeability μ/μ₀ of about 1000.

FIGS. 1A-3 illustrate one embodiment of the present novel technology, a plunger piston assembly 10 typically utilized in pumps, motors or other systems that compress solids, fluids, or the like. The plunger piston assembly 10 generally includes a removable wear sleeve portion 30, a mandrel 40, a housing center 50, and a center pin 60. Previously, when all or part of the piston assembly 10 is worn due to significant compressive forces inherent in the compaction process, the worn part(s) of the piston assembly 10 is/are discarded and the worn components are replaced. The plunger piston assembly 10 allows for replacement of the components to quickly put the piston 10 back into service. This may be done multiple times before the piston assembly 10 has to be replaced with new parts. Therefore, the piston assembly 10 reduces the cost of raw materials, labor and transportation costs, as well as the amount of time the compaction machines are down for repair. The techniques described herein may be adapted to any of number of compaction tooling applications. In addition, the piston assembly 10 and replacement method may be used in other similar compaction embodiments to allow for the use and refurbishment of various materials, typically the ceramic sleeve 30, in high-friction environments. An advantage of the disclosed embodiments and methods is the reuse of a highly machined part instead of replacement of the same, wherein it is, only necessary to replace/refurbish the portion of the piston assembly 10 that is worn. As a result, the life of compaction tooling may be significantly increased and/or the cost of reworking and refurbishing the same may be reduced.

A piston/plunger assembly 10 generally contains a housing center 50, an elongated tubular body typically formed from a single piece of material, the body having a first end 53, a second end 55, an outer surface 57, and an inner surface 59 that defines a plunger receiving a center pin 60. The center pin 60, which is typically disposed inside the housing center 50, is typically made from a structural material, such as the mu-metal doped YSZ material described above, although various metals and possibly other materials, such as tool steel or pre-hardened steel, may be employed and generally includes a first component or a center pin base 63, which is a generally cylindrical component having an aperture 65 in the lower end 67 thereof for controlling the position of the center pin 60, and/or affixing the mandrel 40 to the center pin 60, a ceramic tip 71 that forms the wear surface of the center pin assembly 60. The ceramic tip 71 is attached to the center pin base 73 using a mandrel arbor 75, typically made from tool steel, pre-hardened steel, or the like. As illustrated, mandrel arbor 75 is generally cylindrical, but typically includes either a tapered head at an upper end 77 thereof mated with tapered hole in ceramic tip 71, or a square head mated with counterbored hole in ceramic tip 71, so as to provide a positive engagement between mandrel arbor 75 and the ceramic tip 71.

In the known art, the housing 50, center pin 60, and mandrel 40 were typically permanently affixed in a manner that individual components of the piston/plunger 20 could not be removed or replaced. The piston/plunger assembly 10 permits the quick replacement of any of the piston/plunger components (the mandrel 40, a housing center 50, and a center pin 60) at any time, without having to tear apart the pump, through the use of a removable sleeve 30. The removable wear sleeve portion 30 is typically made of a structural ceramic material such as wear resistant ceramic oxides, although any convenient material may be selected, and is generally shaped and sized to snugly fit the dimensions of a standard piston/plunger 20, although the removable wear sleeve 30 may be sized and adapted to fit any piston/plunger.

To assemble the plunger piston assembly 10, the center pin 60 is typically inserted into the removable wear sleeve 30. The housing center 50 is then attached to the center pin 60 and the mandrel 40 is then cinched down and connected to the center pin 60. This assembly 10 allows the piston/plunger 20 to be used until the piston/plunger is worn from use. Once the piston/plunger 20 is worn, the ceramic sleeve 30 may be removed by removing the mandrel 40 with a wrench, thus releasing the ceramic sleeve 30. A new ceramic sleeve 30 may then be placed onto the pre-existing mandrel 40 and cinched back onto the center pin 60. The use of such ceramic components enables reworking and replacement of the worn tool components. The easy to remove mandrel 40 allows for personnel in the field to easily remove the mandrel 40 and replace the worn ceramic or high wear sleeve 30 in the field. Alternatively, the plunger piston assembly 10 may be swapped out and sent back to the manufacturer to be refurbished and reused at a lower cost.

In some embodiments, cermet bodies of the present novel composition are produced by combining 2-8 weight percent mu-metal powder with a balance of ceramic matrix powder, such as YSZ, to yield a homogeneous admixture. The admixture is formed into a body having a desired shape by hot isostatic pressing (HIPPING) at a relatively low pressure, typically between 500 and 1000 PSI, and at temperatures in the 900° C. to 1500° C. range in a reducing environment, such as flowing dry H₂ or forming gas. This process yields bodies having densities of greater than 99% of theoretical (i.e., less than 1% porosity), more typically greater than 99.2% theoretically dense (less than 0.8% porosity), still more typically greater than 99.5% theoretically dense (less than 0.5% porosity); yet more typically greater than 99.9% theoretically dense (less than 0.1% porosity); and still more typically at substantially 100% theoretically dense (substantially 0% porosity). FIG. 4 illustrates a typical sintering profile.

In some embodiments, wear sleeve 30 is surrounded by a plastic (such as high molecular mass polymers, thermoplastics, thermosetting polymers, amorphous plastics, crystalline plastics, resin-based materials, and the like) retaining belt or sleeve 31 (see FIG. 5). Retaining sleeve 31 offers compression reinforcement to the ceramic or cermet wear sleeve 30 while avoiding the potential for rust or like detritus that may form and then contaminate the pressed bodies. In contrast, a steel sleeve is prone to corrosion and will eventually rust, yielding raised surface structures which both weaken the sleeve and cause friction. Such rust spots result in a buildup of powder that will require cleaning and maintenance, reduce the strength and integrity of the steel sleeve, and can be easily flaked and chipped off to result in contamination of the pressed bodies. Further, stacking tolerances make for difficulty in insertion of the wear sleeve 30 into a steel sleeve, making the product difficult to produce in a high production environment. Further, steel is very heavy, adding to shipping expense and user fatigue and injury.

A polymer or polymer composite sleeve 31 is lighter, cheaper, and easier to produce and is not prone to the flaking/powder contaminant issues inherent with rusty metal. Moreover, the insertion of the wear sleeve 30 into the plastic retaining sleeve 31 it is more forgiving, reducing the need for tight dimensional tolerances that are required for shrink fitting the ceramic in the steel housing. In most cases, the retaining sleeve 31 is molded over the ceramic piece 30. The ceramic sleeve 30 typically has radials or groves pressed in the ceramic, allowing the plastic sleeve 31 to hug the ceramic body 30, thus holding the ceramic body 31 tightly.

Example 2

YST powder was mixed with oxidized mu-metal alloy to yield a homogeneous admixture having 4 weight percent oxidized mu-metal. The powder was pressed into a green body and calcined at 600° C. for 8 hours to debind and remove the oxygen from the oxidized mu-metal. The temperature was ramped to 1400° C. and the calcined body was soaked at 1400° C. for 2 hours to sinter. The sintered body was hot isostatically pressed at 900 PSI in a reducing atmosphere (5% hydrogen gas), after which the body was annealed at 1120° C. for 4 hours, and then ramped to room temperature over 5 hours. The body had a density of substantially theoretical (in excess of 99.9 percent dense), hardness of about 1450 HV, flexural strength of about 200 kPSI, and a relative permeability μ/μ₀ of about woo.

Example 3

YST powder was mixed with mu-metal alloy and a binder to yield a homogeneous admixture having 3 weight percent mu-metal. The admixture was heated in an oxidizing atmosphere to oxidize the mu-metal. The powder was pressed into a green body and plasma sintered at 1400° C. in a reducing atmosphere (dry H₂) for 10 minutes to remove binder and also the oxygen from the oxidized mu-metal and sinter the body. The sintered body was allowed to cool to room temperature with the furnace (natural cool down). The body had a density of 99.5 percent theoretical, a hardness of 1470 HV, flexural strength of 204 kPSI, and a relative permeability μ/μ₀ of 2500.

Example 4

YST powder was mixed with mu-metal alloy to yield a homogeneous admixture having 5 weight percent mu-metal. The admixture was heated in an oxidizing atmosphere to oxidize the mu-metal. The powder was pressed into a green body and plasma sintered at 1400° C. in a reducing atmosphere (dry H₂) for 20 minutes to remove the oxygen from the oxidized mu-metal and sinter the body. The sintered body was allowed to cool to room temperature with the furnace (natural cool down). The body had a density of 99.2 percent theoretical, a hardness of 1450 HV, flexural strength of 200 kPSI, and a relative permeability μ/μ₀ of 2500.

Example 5

YST powder may be mixed without mu-metal alloy to yield a homogeneous admixture. The admixture may be pressed into a green body and plasma sintered at 1400° C. in a reducing atmosphere (forming gas, dry H₂, or the like) for 10-30 minutes to sinter the body. The sintered body may be allowed to cool to room temperature with the furnace (natural cool down). The body will have a density of between about 99.2 and 99.8 percent theoretical, a hardness of about 1470 HV, a flexural strength of about 200 kPSI, and a relative permeability μ/μ₀ of between about 850 and 2500.

While the metal, typically mu-metal, composition is typically held under 20%, compositions are envisioned with sufficient metal or mu-metal phase such that the resulting sintered bodies exhibit metallic electrical conductivity. Such bodies would have contiguity or quasi-contiguity of the metallic phase, and would be able to participate in screening of electromagnetic energy. For example, a functioning Faraday cage may be constructed of high-metal phase cermet pieces.

Bodies formed as described above, particularly those sintered in hydrogen, exhibit the characteristics of having smooth and quasi-polished or polishable surfaces, require substantially less lubrication than metal counterparts, wear evenly with substantially reduced chipping and pitting (than metal or conventional YSZ counterparts). Tooling for pressing pills benefits from high wear resistance, reduced pitting, chipping and rut erosion, reducing and/or eliminating retention of surface material and potential for bacterial contamination.

In one embodiment, the compaction die is utilized on a tablet press and filled with powder with scraper blade and suction from lower punch. Upper and lower punches or like structures may tamp the powder in the die to yield a green body, after which the lower punch lifts and ejects the tablet or body from the compaction die. The parameters of this process are varied (fine-tuned) depending on the equipment and desired finished product.

In the prior art, the compaction die is typically inserted into and supported by a steel retaining belt or ring, the belt having been cut and machined to yield an inner diameter (ID) dimension having very tight tolerance and having a very smooth machined and symmetrical surface. The ceramic or cermet sleeve is also formed to have a very specific outer diameter (OD) dimension with a smooth surface. The metal is then heated and expands, and at this time the ceramic sleeve is inserted in the steel belt or housing (shrink fit). The inside dimension in the ceramic can be core drilled prior to the shrink fit or after. If done before or after the ceramic may crack due to the pressure from the metal shrinking tightly around the ceramic. The required force to hold the ceramic varies per industry. Final machining is then required to remove excess metal and ceramic and bring the die assembly to customer specification. Stacking tolerances and proper surface parameters make this product difficult to manufacture in a high production environment. Another drawback of the prior technology is that the steel is reactive and typically develops rust spots, which manifest as raised surface features and thus have the potential to cause friction. This typically gives rise to a buildup of powder, and increases the need for frequent cleaning and maintenance. The rust also reduces the strength and integrity of the die, is easily chipped, and causes contamination. In addition, the steel banding makes the die assembly very heavy for both the operator to use and the manufacturer to ship.

In operation of this embodiment, a cermet die assembly is inserted into and supported by a polymeric or plastic housing. The insertion process is much more forgiving and reduces the need for tight specifications for shrink fitting the ceramic or cermet die assembly into the housing. The cermet die assembly requires less stringent dimensional tolerances (i.e., bigger window) as the plastic support belt or housing may be directly molded over or onto the ceramic. The ceramic or cermet die assembly typically includes radials or groves formed thereinto for engaging the plastic housing so that the housing “hugs” the cermet die assembly for a glove-like fit. Production time and difficulty are both reduced, thus reducing the per-part cost as well. The product failure or reject rate is likewise reduced significantly, along with the risk of catastrophic failure when the die assembly is in use. Further, the weight of the supported cermet die assembly reduced to about one-half, more typically to about one-third, of that of its steel banded counterpart.

In many embodiments, the cermet material is sufficiently electrically conductive that the cermet bodies may be machined via electric discharge machining (EDM) techniques with high precision and at room temperature. EDM machinability is significantly quicker and less expensive than traditional grinding techniques for yielding high-precision ceramic workpieces. In particular, wire-cut EDM techniques may be applied to yield intricate features in the cermet body.

The relatively high, metallic or quasi-metallic electrical conductivity of the cermet powders and bodies makes them uniquely qualified for service as both EMF and physical or structural shielding for electronic devices, personal use (such as EMF filtering earplugs or helmets), and the like. Further, the material may have an electrically insulating surface or portion when combined with a layer of insulating material, such as alumina or mullite. Such bodies could be formed as unitary pieces or as multipiece composites.

The sintered, EDM-friendly body will typically have a density of substantially theoretical (in excess of 99 percent, more typically in excess of 99.9 percent dense), bulk density of about 6.1 g/cc, hardness of about 1150-1250 HV, flexural strength of at least about 200 kPSI, compressive strength of about 2000 kPSI, toughness of 10-14 MPa·m^(1/2) (K1c), modulus of 270-290 GPa, and a relative permeability μ/μ₀ of about woo.

Green bodies formed from cermet powder precursors via CIP, HIP, hot pressing, injection molding, casting or like processes may be formed to near-net shapes, often without the need for binders. These green (and typically binder-free) bodies may be precision machined into complex shapes as green bodies, calcined bodies or fully dense sintered bodies via EDM machining, taking advantage of both the toughness and hardness of the cermet materials and their bulk electrical conductivity for precision machining and polishing. The lack of a binder requirement likewise typically reduces both shrinkage and calcination/sintering cycle time.

The cermet bodies tend to have slick, smooth surfaces that are self-lubricating, giving punches and dies the advantage of requiring less, if any, lubricant that might otherwise contaminate powders and green bodies, as well as reducing the tendency of powders to stick to punch and die surfaces. Cermet tools thus require less frequent maintenance than do steel counterparts.

Metal leaching tests have yielded results indicating that the novel cermet material loses substantially less metal than tool steel under ASTM Method C738-94 test conditions.

TABLE 1 YSZ body Ni: 0.00 ng Ni/mm² Fe: 0.04 ng Fe/mm² Mu-metal Cermet body Ni: 1 ng Ni/mm² Fe: 1 ng Fe/mm² Tool Steel body Ni: 30 ng Ni/mm² Fe: 70 ng Fe/mm²

In a further embodiment of the present novel technology, a production plastic housing and/or ceramic insert may be created and/or used. Such embodiment(s) are depicted in FIGS. 5 & 6.

Many tooling systems utilize legacy materials to produce tooling that is outdated. This embodiment fills the needs of industry that requires tooling that has an extremely long service life (ceramic oxides, carbides, nitrides, graphene, graphite, and combinations thereof, and other similar materials, as well as heat treated and coated materials) with low-cost holding systems that support the tooling body to keep it strong and secure in place, and are typically light weight, inexpensive, easily mass produced and/or color coded to easily identify product.

Applications:

Core rods, punches, compaction die, tablet tooling, draw and extrusion dies are among tooling that benefit from long service life so as to keep production lines operational without frequent excessive down time, including pharmaceuticals, batteries, food production, metal stamping, food and beverage, and the like.

Example: Compaction Die

The compaction die is utilized in the production of tablets utilized in, but not limited to, the following industries: battery, pharmaceuticals, nutraceuticals, food, cosmetics, beverage, confectionary, food, pet food, chlorine, and/or industrial tablets. The dies are commonly used on tablet presses where and upper and lower punches converge within the die to compact powders to produce tablets. The slick ceramic surface typically helps to keep powder from wearing and sticking to the ceramic. The ceramic keeps the line down as the tooling wears considerably less, and the plastic housing securely holds the tooling in place, reducing the overall cost of the tooling assembly and providing for color coding to more readily identify a specific product being manufactured.

Typically, the compaction die is utilized on a tablet press and filled with powder, such as via scraper blade and suction from the lower punch. Upper and lower punches or other devices may tamp the powder in the die, and then the lower punch lifts and ejects the tablet or pressed green body from the compaction dies. This exact process may be altered depending on the equipment and desired finished product.

Example 2: Core Rod

In the production of alkaline batteries, manufacturers are challenged with building stronger and tougher batteries. The battery strength usually arises from the amount of powder used as well as from very aggressive battery powder compositions that deteriorate conventional tooling. Hence the wear portion is typically made from ceramic oxide, carbide, nitride, and/or a heat treated or coated tooling. This provides a working or service life multiple times that of typical hardened tool steel. Plastic is utilized to provide the holding of the wear material in place as well as to provide low-cost and lightweight options to produce and ship. Color coding again may be utilized to differentiate one product in production from another.

Extrusion dies and dies for producing wire are other examples of disparate material such as edibles (cheese, pasta, and the like) or structural materials (metals) may be extruded or pulled through ceramic dies to form or reduce the thickness of material. Plastic support structures for said dies may be prepared by incorporating high magnetic permeability metal particles for detectability and/or fibers, whiskers, or carbon nanotubes to reinforce their strength.

Prior art technology traditionally combines a ceramic or desirable high-wear resistant material as an insert within a steel support housing. In most cases the steel is cut from a solid and machined to the inside and outside dimension under very close tolerance. The surface must also be extremely smooth. The ceramic must be machined to very specific dimensional tolerances and also with a smooth surface and true and symmetrical. The metal is then heated to expand the preferred void space for receipt and acceptance of the ceramic tooling. Once the ceramic tooling is inserted in the steel housing, the housing is cooled to contract the housing onto the ceramic tooling to yield a shrink fit. The required force to hold the ceramic in the steel varies per industry and application. Stacking tolerances and proper surface make the product difficult to manufacture in a high-production environment. This is a slow and tedious process, and thus an expensive one.

Steel is corrosive and will eventually rust and deform the surface, giving rise to friction. This will result in a buildup of powder that will require cleaning and maintenance. The rust also reduces the strength and integrity of the die and can be easily chipped and cause contamination. The stacking tolerances make the product be difficult to produce in a high-production environment. Further, steel is very heavy, such that a standard die assembly incorporating a steel housing weighs about 325 grams, in contrast to an assembly with a plastic housing weighing about 125 grams. The weight reduction is much easier for the operator on the production floor to hold in their hand and carry in box loads on the floor, not to mention reduced shipping costs.

According to the current novel technology, a ceramic insert is placed within a mold and plastic is quickly injected or otherwise flowed around the ceramic tooling. The plastic quickly hugs the outside of the ceramic tooling body. There is no tight tolerance requirement of the ceramic body as the plastic conforms to and accepts the outer diameter. The machining of the ceramic and surface are no longer requisite as the plastic fills the gap tightly around the ceramic insert and a roughened or irregular ceramic surface may in fact be preferable for adhesion of the plastic support body. The cost is significantly lower as the materials are less expensive and production times are shorter. Scrap from the machining of the metal ID in the housing is not part of the new process as the plastic fill around the parts and little scrap is generated.

The ceramic may be designed with grooves or like surface features that interlock with the plastic to hold it to the ceramic tooling body and retard slippage. Metal components in the core rod utilize arrow type or other designs to anchor the materials together to insure there is no slipping. In some applications a cross pin, glue, or ultrasonic welding or the like may be utilized to secure parts tightly together.

The ceramics may be fortified with whiskers, carbon nanotubes, graphene, or like additives to provide strength, hardness, toughness, and/or optimized wear properties. The ceramic tooling bodies may be sintered or calcined nitrogen or like atmospheres to provide extra surface lubricity or in a hydrogen atmosphere to densify and clear any impurities as well as HIP material under high pressure and heat to bring material to maximum density.

The plastics are typically chosen from common structural formulations, but may be fortified with glass, carbon nanotubes, carbon fiber, graphite, graphene, or ceramic powder, and combinations thereof to enhance the properties of the tooling to meet the design requirements. In cases where the product is used in the production of pharmaceuticals or food or similar, metal detection powders (as described above) may be added to the plastic. The so-produced assembly will then meet CFR 21 and be certified for use in pharma and food production.

In some embodiments, a polytetrafluoroethylene (PTFE) plastic is sleeve material is enhanced with metal detection materials as recited above to provide a product with a very low coefficient of friction while also exhibiting the metal detection qualities required by a specific industry, such as pharmaceutical, food preparation, or the like. Highly magnetic and low coefficient materials are added at levels sufficient for detection but insufficient to disrupt the PTFE low coefficient, making the resultant PTFE composite material safe and usable for these sensitive Industries. These solid products can be molded to an exact shape requiring minor machining, hence providing the entire parts to be produced by injecting molding or the like to yield finished or nearly finished parts with intricate features that would be very difficult and expensive to produce from steel or ceramic alone. Such parts include rounds, ovals, and the variety of shapes that are utilized by the pharmaceutical, food and like industries. Any required machining is quickly and easily done, as plastic is relatively soft and easy to machine. Carbon fibers or other materials can also be added to provide toughness and strength to the PTFE composite material.

While the plastics are typically chosen from common structural formulations, the plastic formulations may be fortified with materials such as glass, carbon nanotubes, carbon fiber, graphite, graphene, or ceramic powders, and combinations thereof to enhance the properties of the resultant composite material tooling to meet specific desired design requirements. In cases where the composite tooling is used in the production of pharmaceuticals, food or similar products, metal detection powders (as described above) may also be added to the plastic composite. The so-produced composite tooling assembly will then meet CFR 21 and be certified for use in pharma and food production

The new technology combines a ceramic or desirable material insert into the plastic housing. The process is much more forgiving and reduces the tight specifications required for shrink fitting the ceramic in the steel housing. The ceramic actual size and dimension offer a wider window as the plastic is applied and molded over the ceramic tooling body. The tension requirement from the steel shrink fit process, squeezing the ceramic walls, is eliminated as is the effect of stacking tolerances. The ceramic may be used as produced (unmachined) or may be provided with radials or grooves formed therein allowing the plastic to hug or grippingly interlock the ceramic like a glove, holding the ceramic tightly. The time to produce the ceramic/plastic parts is about a tenth of time required to produce corresponding metal/ceramic parts, and the cost is less than a tenth as well. The product failure or reject rate is reduced significantly along with the risk of catastrophic failure. The cost to produce is significantly reduced and throughput is greatly increased.

The novel assembly is about one-third of the weight of the traditional technology and significantly less costly to manufacture. Therefore, the invention provides a product that is less expensive to the customer in product cost and freight. The materials that utilized are not corrosive and will not rust. The dies under this novel invention are less likely to be damaged in production or if they are dropped due to the new manufacturing process and the reduced tension on the ceramic insert. The plastic acts as a built-in shock absorber if dropped. Maintenance crews will suffer less from the fatigue of lifting the heavy parts all day that can cause carpal tunnel syndrome and other issues associated with repetitive lifting of weight in same motion.

While the novel technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the novel technology are desired to be protected. 

I claim:
 1. A tooling assembly, comprising: a cermet tool body; and an electrically nonconductive polymer support body at least partially encapsulating the cermet tool body; wherein the cermet tool body and electrically nonconductive polymer body further comprises a plurality of high magnetic permeability metallic particles distributed therethrough; wherein each respective high magnetic permeability metallic particle has a magnetic permeability of at least 0.0001 H/m; and wherein each respective high magnetic permeability metallic particle has a relative permeability of at least
 100. 2. The tooling assembly of claim 1 wherein the magnetic metallic particles are mu-metal.
 3. The tooling assembly of claim 1 wherein the cermet tool body has a compressive strength of at least 2000 kPSI, a modulus or at least 270 GPa, and a minimum toughness of 10 MPa·m^(1/2).
 4. The tooling assembly of claim 3 wherein the cermet tool body is a bulk electrical conductor having sufficient electrical conductivity to be EDM machinable.
 5. The tooling assembly of claim 1 wherein the cermet tool body is selected from the group comprising ceramic oxides, carbides, nitrides, graphene, graphite, and combinations thereof.
 6. The tooling assembly of claim 1 wherein the cermet tool body has a density in excess of 99 percent, bulk density of about 6.1 g/cc, hardness of about 1150-1250 HV, flexural strength of at least about 200 kPSI, compressive strength of about 2000 kPSI, toughness of 10-14 MPa·m^(1/2) (K1c), modulus of 270-290 GPa, and a relative permeability μ/μ₀ of about
 1000. 7. The tooling assembly of claim 1 wherein the electrically nonconductive polymer support body is reinforced with reinforcements selected from the group comprising glass, carbon nanotubes, carbon fiber, ceramic powder, graphene, graphite, and combinations thereof
 8. The tooling assembly of claim 1 wherein the cermet tool body further comprises a roughened outer surface.
 9. The tooling assembly of claim 1 wherein the electrically nonconductive polymer support body grippingly interlocks with surface ridges formed on the cermet tool body.
 10. The tooling assembly of claim 1 wherein the electrically nonconductive polymer support body is color coded.
 11. A method of making a tooling assembly, comprising the steps of: a) positioning a tooling body in a mold; and b) molding a plastic shell at least partially around the tooling body; wherein the plastic shell includes a plurality of dispersed high magnetic permeability metallic particles therein; wherein each respective high magnetic permeability metallic particle has a magnetic permeability of at least 0.0001 H/m; and wherein each respective high magnetic permeability metallic particle has a relative permeability of at least
 100. 12. The method of claim 11 wherein the plastic shell further comprises a plurality of reinforcing particles dispersed therein; and wherein the plurality of reinforcing particles is selected from the group comprising glass, carbon nanotubes, carbon fiber, graphite, graphene, ceramic powder and combinations thereof. 